PROJECT SPECIFICATION SP0579 - ETOILE COPPER PROJECT MECHANICAL GENERAL MECHANICAL INSTALLATION 00 [penina Issued for Use fee REV | ISSUE DESCRIPTION Page 1 of 20 ‘$P0579-0000-0M5-01 ee |SENET ‘SP0579.0000.0945.01 GENERAL MECHANICAL INSTALLATION REV 00 26-11-14.d00 CONTENTS 41 GENERAL 1.1 PURPOSE... ccs 1.2 DRAWINGS... 1.3 LEGAL REQUIREMENTS... 1.4 PERFORMANCE... 1.8 NOISE... 4.6 IDENTIFICATION TAGS a 1.7 RECEPTION AND HANDLING OF MATERIALS...... 1.8 INTERFACE WITH OTHERS... 1.1 WELDING : 1.2 PRESSURE VESSELS AND PI PIPIN 1.3. LIFTING EQUIPMENT... 2 MATERIALS. 2.4 GENERAL. 3. GENERAL INSTALLATION REQUIREMENTS. 3.1 SECURITY nscsccceeen 3.2. ASSEMBLY OF EQUIPMENT 3.3 INSTALLATION AND ERECTION . Se 3.4 EQUIPMENT ALIGNMENT AND ADJUSTMENT. 7 ate 3.6 ALLOWANCES AND TOLERANCES: 3.6 SPEED REDUCERS AND MOTORS. 3.7 HAND ROTATION PRIOR TO COUPLING...... i 3.8 PREPARATION OF FOUNDATIONS AND PACKERS.. 3.9 EQUIPMENT MOUNTING BOLTS: 3.10 GROUTING....... 3.11 LIFTING LUGS... esse 3.12 SUPPORTS AND BRACINGS. 3.13 SAFETY DEVICES. 3.14 LUBRICATION AND CLEANING..... 3.15 CLEANING. 3.16 PAINT TOUCH-UP.. 4 SAFETY. Page 2 0f2012 1.3 4.34 1.3.2 1.3.3 44 15 SENET ‘5PO679-0000-0N5-01 GENERAL MECHANICAL INSTALLATION REV 00 26-11-14.d0 GENERAL PURPOSE The purpose of this specification is to define the Conditions and requirements related to the material quality, work execution and equipment installation methods and mechanical systems. This specification shall be used with the general clauses and other specifications being an integral part of the contractual documents. DRAWINGS Ensure the receipt and verification of all up-dated drawings related to the complete installation of each system, equipment or other accessories. Immediately inform the Engineer, in writing, of the receipt of any revised drawings or additional clauses. LEGAL REQUIREMENTS All works shall comply with the South African Occupational Health and Safety Act. Codes and Standards PD §304 Code of Practice for the Safeguarding of Machinery AWS D1.1 Structural Welding Code Contract Specifications ‘The work shall be performed in accordance with the specifications listed in the Document List for the Contract. PERFORMANCE ‘The work covered in this specification shall be executed by proven competent Contractors in similar work and using qualified labour. NOISE Equipment emitting composite A-weighted continuous sound levels, when installed, shail be as specified in the OHS Act, Where this is not reasonably practicable the tenderer shall advise the Engineer in his tender of the proposed method of noise abatement. As a minimum, the following corrective actions shail be taken to safeguard workers: * Boundary areas of high noise levels shall be clearly demarcated by posting signs in the noise zone areas (in conspicuous places, which are entries and exits). if marked boundary areas alone are impractical, then acoustic barriers, with the required signs, shall be considered * During pre-commissioning or commissioning activities, ear protection for all Personnel is required when entering the noise zone. This shall be for the sole Page 3012017 SENET ‘SPOS/9-0000-0015.01 GENERAL MECHANICAL INSTALLATION REV 00 26-11-14.doe use of each individual and shall be kept in a clinically clean environment to ensure its use does not result in the spreading of infectious or contagious diseases. * Ear protection shall be provided if the equivalent continuous sound level is equal to or above 85 that which is specified in the OHS Act. Note: “Composite” means that if there is more than one item, then all items together shall emit less than the specified equivalent continuous sound level. “Equivatent continuous” means the sound level integrated over any 10 minute period which is equivalent to a continuous sound level of the same magnitude, measured with an integrating sound level meter (Lea) IDENTIFICATION TAGS, All equipment and major components have an identification tag. Contractors shall not remove those tags and shall take measures to keep identification plates clean, visible (when installed) and undamaged until the equipment is transferred to the Owner. Following paint touch up, equipment, conduits and chutes must be identified with the appropriate tag numbers as shown on drawings. RECEPTION AND HANDLING OF MATERIALS. Site shall check packaging for damage during transport. Once the equipment and materials have been received and transferred, Site will assume all further responsibilities for protection, storage and handling, The lifting and handling of the machinery and equipment shall be as per ‘manufacturers recommendations, All overhead lifting of equipment and / or ‘machinery shall be carried out by a qualified rigger using approved registered lifting equipment and slings. When required, machined surfaces and other fragile components shall be protected with soft material, such as wood, rubber etc. All equipment and material which has been un-crated and unpacked for inspection Purposes shall be protected and stored adequately until installed. All motor and gearbox shaft extensions shall be coated with a layer of anti-corrosion grease / paste, shaft keys shall be securely bound to the respective shaft using a suitable tape. Interior of equipment shall be Kept clean and sealed where possible, conduit ends and hoses shall be plugged and Kept free from dirt or foreign matter at all times. While in storage or when handling and transporting, the equipment, accessories and Conduits shall be adequately supported to avoid permanent deformations and other damages. Page 4 of 201.8 14 1.2 13 4d 1.41.2 Sener ‘SP0679-0000-0MS5.01 GENERAL MECHANICAL INSTALLATION REV 00 26-1 {-14.d00 ‘As the work progresses, equipment, components and conduits, which will not necessarily be connected to the other equipment during the day, shall be protected against any penetration of water or other foreign material until the installation is transferred to the Client. INTERFACE WITH OTHERS Before the installation of equipment the Site shall survey the work of others to insure that foundations, anchor bolts, wall openings, floor sleeves, and mounting holes are in confonnity with specifications and drawings. Site shall inform the Engineer promptly of any discrepancies prior to equioment installation. WELDING For all welding work refer io specification $P0879-0000-0M5-05. PRESSURE VESSELS AND PIPING All vessels that qualify as pressure vessels shall be re-tested after installation, The Installation Contractor shall, in conjunction with an Approved Inspection Authority test the vessel to code. A certificate of compliance shall be obtained from the AIA and shall be included in the mechanical completion documentation. For piping refer o $P0579-0000-0PS-01: Specification for Design, Fabrication, Erection and Testing of Piping and Valves. LIFTING EQUIPMENT Initial Overload testing of Lifting Equipment This shall be done as follows: a) Testing by the Manufacturer When the manufacturer of the equipment is responsible for the on site test the mechanical installation Site shall assist the manufacturer in handling the required test weights and provide a qualified crane operator for the duration of the test. b) Testing by the Contractor When the certification is not the responsibility of the manufacturer, Site shall carry out the testing that is legally required and set out below:- Inspection criteria Lifting equipment shall be examined and performance tested by a qualified crane tradesman / technician prior to load testing and commissioning as per the OHS Act, This shall include but not be limited to the following: Page 5 of20Sener ‘SP0579.0000-0M5.01 GENERAL MECHANICAL INSTALLATION REV 00 26-11-14.doe «Fully functional test ail motions: Hoist up / down Crab cross travel left / right Long travel left/right * Fully functional test to insure that all motor speeds work: in forward / reverse. * Full functional test that all motion motors brake within the required distances * Full functional test: Overdrive all motions to ensure that limit switches de energise and arrest the respective drive motions correctly * Emergency stop: Must arrest all motions and de-latch all drive contactors. 1.44.3 Legal requirements 32 3.3 All lifting equipment ie. cranes / hoists etc shall be load tested by an Approved Registered Lifting Authority using Registered Approved Equipment. + Tests weights shall be 110% of the designed "Safe Working Load”, deflection shall be in compliance to the manufacturer's specifications and noted in a crane register book, unless this code is more stringent. + Aload test certificate shall be issued which includes:- Crane Serial number / equipment number Nature of test Safe Working Load Technician / tradesman Date Time Refer to the British Standard Specification BS 466: Specification for Power Driven Overhead Travelling Cranes, semi Goliath and Goliath Cranes for General Use. MATERIALS GENERAL Material selected shall comply with drawings and technical data. GENERAL INSTALLATION REQUIREMENTS ‘SECURITY Site shall apply the required security measures for all the work performed, ASSEMBLY OF EQUIPMENT Assemble on site all equipment and componenis as per manufacturer's recommendations and in certain specific cases under the supervision of its representative INSTALLATION AND ERECTION Site shall verify all dimensions and locations of equipment shown on drawings and ensure that there is sufficient clearance with other works. Page 6 0120SENET ‘SP0579.0000.0M5.01 GENERAL MECHANICAL INSTALLATION REV 00 26-11-14 doc The aligning of equipment by means of sledgehammers or similar implements is strictly prohibited. Subject to the Engineer's approval, nuts may be welded to base plates and bolts used for fine adjustments. Establish the alignment and mark the location of the anchor bolts with respect to the holes on the base plates. Drill holes in concrete as specified and indicated on drawings and specifications. Obtain the Engineer’s approval before drilling holes in structural steel or concrete in order to be able to fit base plates, leg supports etc. of the equipment. Install, align and level the equipment as per installation drawings and manufacturer's recommendations. Alignment, levelling and the verticality on equipment shall be in conformity with drawings, norms and codes. ‘The equipment shall not be modified nor repaired; no buming or welding shail be allowed on any part of the equipment without a written consent of the Engineer. Any equipment bolted to the structure shall have, when practical, the bolt head on top of the fixing bracket. All service connections water, air or others to the equipment shall be visible and accessible. 3.3.1 Welding of Steel Installed equipment which incorporates anti-friction bearings or load cells, shall not be welded on unless welding is absolutely necessary. Site shall request approval in writing from the Engineer before such welding is performed, Preferably, bearings shall be removed or electrically insulated during welding. If this is not possible and welding must be performed with bearings in place, locate the earth lead to provide the minimum current flow through the bearing and as far as possible from the bearing location. Load cells shall be removed before any welding is done. Welding shall not be allowed while rigging is attached to equipment. 3.3.2. Burning and Cutting Burning or welding on building structures is prohibited. Drilling on structures shall be done only with the written approval of the Engineer. Cutting with a flame torch, where approved, shall be done in a neat, professional manner and at least 2 mm shail be allowed to be ground smooth after cutting to ensure a surface free of stress concentration, Lines to be cut shall be laid out with straight edges. All cut edges and corners shall be cleaned of scale and ground smooth. Page 7 0f203.3.3 3.3.4 33.4.4 SENET 'SP0S79.0000-OME-01 GENERAL MECHANICAL INSTALLATION REV 00 26-11-14.doe Fire blankets or other protection shall be provided to prevent cutting, welding and grinding sparks from falling onto lower levels and other equipment. Care shall be taken to ensure that stainless steel components and piping do not become damaged by sparks or slag. Flame cutting of boltholes is prohibited, Site shall be responsible for safely of personnel and all equipment during any Welding or cutting. Gaskets Where gaskets are installed between joints of chutes and equipment, they shall, unless otherwise stated, be 3 mm thick neoprene, full flange width, punched to match flange bolt holes. Each gasket shall be made up of single thickness material and shall be no more than one piece per leg of the peripheral length to be joined. In the case of piping, gaskets shall be full flange width except in the instance of a raised flange where only the raised face shall be covered. Pipe gasket material and design shall be approved by the Engineer. Installation Sequence Site shall be responsible for any verification and testing during construction to satisfy the Engineer in effect that the equipment has been erected to specifications and drawings. This inspection shall be done in sequence as follows: Step 1- Installation of equipment Step2- Levelling of equipment and base plates, Step3- Pouring of grout Step4- Assembly of service piping Step5- Preliminary alignment of coupling Step 6 - Lubrication Step7- General mechanical installation Step #1 Installation of Equipment Site shall be in possession of all necessary documentation prior to the installation of equipment, such as: 1) Positioning and elevations as per drawings and specifications. 2) Verification of packers and shims. 3) Verification of the bolt toraue. 4) Cleaning and preparation of foundation base to recelve equipment. Page 8 ef203.3.4.2 3.3.4.3 3.3.4.4 33.4.5 Sener ‘SP0579-0000-0MS-01 GENERAL MECHANICAL INSTALLATION REV 0 26-11-14 doc ‘Step #2 Primary Levelling of Equipment and Base Plates The verification of the equipment level andior base plates shall be made from machined surfaces, ‘The packers and shims shall be as described in Section 3.9. ‘Step #3 Pouring of Grout The pouring of grout shall be described in section 3.10. Step #4 Assembly of Service Piping Install all piping, chutes and others and assemble to equipment. When temporary strainers have to be used for pipeline flushing, replace the strainer element by a clean one after flushing, When completed, disconnect ail piping from equipment and check for mis- alignment and correct as required in such a way that no stress is transmitted to the equipment when final connections are made. Step #5 Preliminary Alignment of Coupling Site shall ensure that the equipment is rigidly fixed to the foundation before coupling alignment is started. Coupling alignment shall be performed using dial indicators unless otherwise specified During the process of alignment, the equipment shall be free from any outside stress or forces, The tolerances for angular and parallel alignments shall be as specified in Section 3.5. Both halves of the coupling shall be rotated, keeping the same relative Position. ‘The readings shall then be recorded on the appropriate form and submitted to the Engineer. (Rotating Equipment Alignment Inspection Report). After the readings are completed, all accessories such as piping chutes ete, related to the equipment shall be reinstalled to the equipment and new readings shall then be taken and recorded, Following the second coupling readings, any differences from the first readings indicate that accessories exert a certain stress to the equipment, Any miss-alignment resulting from the installation of the accessories shall be corrected by adding or relocating supports. Gear and sheaves shall be in line and parallel to each other. Do not at this stage assemble the coupling, gear and sheaves components to the motor. Page 9.203.3.4.6 33.4.7 3.3.4.8 SENET ‘SP0579.0000.0N6.01 GENERAL MECHANICAL INSTALLATION REV 00 26-11-14.doe Couplings, sheaves, gear, chain wheels etc, The installation of these elements shall be as per manufacturer's recommendations. Boring shall be as per manufacturer's recommendations or depending on the type of key used, free slicing or forced. Tolerances are set by the manufacturer. The keys and key slots are normalised. The machine shafts and the components shail be cleaned before assembly. The fitting of the parts together shall be made using adequate mounting arrangements as specified by the manufacturer. Site shall ensure that the equipment Is rigidly fixed to the foundation before coupling alignment is done. The shafts shail be aligned in such a way that the radial, the axial and the angular deviations of the shafts be the smallest possible and less than the deviations allowed by the manufacturer. The deviations shall be measured using straight edge or a dial indicator. The alignment, deviations, all the mountings using screws, the torque of the bolts shall be controlled before start-up, Bearings For equipment, which is supplied with bearings installed, Site shall carefully inspect bearings to confirm that they have been adequately blocked and that no bearing damage has occurred. If bearing damage is discovered or suspected, the matter shall immediately be reported to the Engineer. Dismantling and re-assembly shall comply with the bearing manufacturer's instructions. All bearings provided with adaptor sleeve mounting shall be checked for location and tension prior to final installation of the equipment, Radial clearance of bearings shall be checked and recorded by Site. Misalignment of roller bearings shall not exceed 0.001 mm per mm slope through the bearing. All bearings shall be checked to confirm that they have been factory lubricated and to ascertain that the lubricant is still uncontaminated. If not, they must be lubricated in accordance with the manufacturer's requirements or the lubricant must be changed. Installing Hubs, Pinions and Sprockets on Shafts Where mating components, such as hubs, pinions or sprockets are delivered to the site separately from shafts and site installation is required, forcing these components onto shafts by hammering or similar means is prohibited. Fitting shall be achieved by following the manufacturers installation instructions, In general, mating components shail be installed on their shafts in accordance with the Manufacturer's installation instructions. Where the class of fit is not Page 10.0203.3.4.9 SENET 'SP0578.0000-045-01 GENERAL MECHANICAL INSTALLATION REV 00 26-11-14.doo. available on drawings or from manufacturer's instructions, interference fit of H7-p6 for ferrous parts and H7-s6 for low modulus of elasticity materials (e.g, light alloys) shall be used. Where mating components are an interference fit on shafts, they shall be heated in a controlied temperature environment (such as an oven or oil bath), then be slid on to the shaft and installed in the correct position. The temperature to which components are heated shall not exceed 200°C without written permission from the Engineer. Where installation is by the injection method, Site shall ensure that supervision is by experienced personnel and that only approved equipment is used. The position of hubs and the tension of compression bolts for "Ringfeders" or similar locking devices shall be checked prior to installing equipment. V-belts Drives and Chain Drives Prior to installation of belts or chains, parallel alignment of shafts shall be checked by placing a straight edge across the face of the sheaves or sprockets. Horizontal alignment may be achieved by placing a square with a spirit level in the horizontal arm, against the face of the sheave. Alignments shall be measured with feeler gauges and tolerances shall comply with manufacturer's instructions. When supplied, Site shall ensure that belts are installed as matched sets. All oll, grease and rust shall be cleaned from sheave grooves before belts are installed. Belts shall be installed by reducing the distance between shaft centrelines and hand fitting belts over sheaves. Under no circumstances shall belts be rolled into position or be forced onto pulleys with crow bars, wedges, screwdrivers or other implements. The V-belt drive must be properly tensioned. Required steps for proper tensioning are: + Adjust take-up until belts are seated and start the drive. When full speed is reached, adjust the take-up until only a slight bow appears on the slack side. Measure the span length. * With drive stopped, apply a force (perpendicular to span al centre of the span), required to deflect the belt 0.16 mm per om of span length, The force can be applied by means of a simple spring scale. * Compare the force required with data supplied by the manufacturer or in the absence of such data, with the following table. ‘The force required should be within the minimum and maximum values. A new set of belts shall be initially tensioned in accordance with the following table and shall be re-tensioned after about 30 hours of operation. The tensioning report shall be submitted to the Engineer. Page 11 of 20SENET 'SP0S79.0000OMS-01 GENERAL MECHANICAL INSTALLATION REV 00 26-11-14.doe [Bett [GD of Small] Force(kg) —*+? Section Sheave (mm) Minimum | Maximum | ioN(sP2) | 6795 | 10 | 18 | 100 to 140 15 20 TRN (SPA) 80 to 132 20 27 140 to 200 28 35 16N (SPB) ~T41 to 224 3.5 54 a 236 to 315, leat 66 22N (SPC) 224 to 355 64 9.2 375 to 560 92 122 2ENDELTA | 05 & Above 153 204 0X6 @ 56 t0 100 08 08 13X8(A) | 80to 140 10 15 f 47X 17 (8) 425 to 200 2.0 see 22 X 14 (C) 200 to 400 44 6.4 32X19 (D) 335 to 660 74 10.7 3.3.4.10 ‘Step #6 Lubrication Site shall take all reasonable precautions to prevent contamination of lubricants and shall lubricate the equipment as per the lubrication dala sheets supplied by the Engineer or by the equipment supplier. Flushing oil shall be removed and gearboxes shall be cleaned with rinsing oll as specified in the lubrication data sheets supplied by the Engineer 3.3.4.1 Step #7 General Mechanical Inspection Prior to the commissioning activities, the Site pre-commissioning team shall perform the following inspections: Equipment installed as per drawings. Motor and drive components properly bolted to the base. Equipment properly bolted to foundation/and or structural steel. Physical interference. Equipment alignment. V-belt proper tension, Safety guard adequate. Free rotating motion of equipment. Dowelling, Page 12.0203.4 3.5 3.54 3.5.2 SENET '80S79.0000-0145.05 GENERAL MECHANICAL INSTALLATION REV 00 26-11-14.¢oe EQUIPMENT ALIGNMENT AND ADJUSTMENT Verify and correct if required all mechanical components, which have been assembled in the shop and report by writing any misalignments, Inform the alignment and final adjustment of equipment and components after base supports have been subjected to deformation by stress under maximum load. For equipment, machines and components mounted on structural steel bases, drill pilot holes to permit adequate fiting and the preliminary bottling of the surfaces in contact, then drill holes corresponding to the minimum tolerance required for the bolts selected and tighten Ream pilot holes to dimensions and install locating dowels. On written approval from the equipment Supplier and the Engineer, Site may make adjustments and / or minor modifications required for good workmanship of the equipment, The cost involved shail be absorbed by the faulty responsible party. In special cases, the Engineer may ask the Supplier to make the necessary modifications. ALLOWANCES AND TOLERANCES Fixed Elements The following tolerances shall apply to the position of conduits, chutes etc. and also to the Junctions of such items, unless otherwise stated on supplier's drawings. ° Axis 3 mm measured from reference lines * Elevation 3 mm measured from reference levels * Horizontally 3 mm measured over a length of 9.000 mm * Vertically 3 mm measured over a height of 9 000 mm General Equipment, Blowers, Compressors and Fans Equipment shail be installed to the following tolerances, unless noted otherwise in the main Technical Specification or manufacturer's installation instructions. * Lateral Location Within 1 mm of true centreline. * Longitudinal Location Within 2 mm of true location shown on drawing, * Height Within 1 mm of required elevation, Page 13 of 20SENET ‘SP0579.0000.0M5.01 GENERAL MECHANICAL INSTALLATION REV 00 26-11-14 doe . Squareness (Looking down in plan view): Within # 0.5 mm/metre of true squareness to the equipment centreline (ie. if the width of a roller is 1 metre, the maximum out of square reading is 0.5 mm over the length of the roller to the true equipment centreline), * Level (Lateral and Longitudinal) Within « 0.5 mm/metre of level. Level difference between matching pieces of equipment shall not exceed 2 mm at the interface. 3.6.3. Coupling Alignment Coupling alignment shall be checked prior to final assembly at each coupling. Couplings shall be aligned to either situation 1 or situation 2 below, or manufacturer's recommendations if tighter than those listed below. Situation No. 4. - Coupling Tolerances for all Major High Speed Couplings: All motors above 18.5 KW (25hp) or above 1500 rpm, Maximum allowable shaft eccentricity 0.05 mm (that is a maximum total indicator reading of 0.10 mm.) Maximum allowable face to face error 0.20 mmimetre of coupling face. Situation No. 2. - All other couplings Pump Couplings ‘When a motor is aligned to a pump, the alignment shall be rechecked after the pipe work is reconnected to ensure the pipe work has not distorted the pump casing. Any other cases involving variations from these tolerances shall be referred to Engineer. Records When requested coupling alignments shall be witnessed. In all cases a “Rotating Equipment Alignment inspection Record!” shall be filled out and forwarded to the Engineer for approval. (Refer BSS 0000-M-101 page 9), Situation No. 3- V Belt and Chain Drive Alignment Offset - ‘Same as for situation No. 1 above, Angular offset - Same as for situation No. 1 above. Axial play - Less than offset Page 14 0f20SENET 'SP0579.0000.0M5.01 GENERAL MECHANICAL INSTALLATION REV 00 26-11-14.doe Situation No. 4 - Levelling of machine elements on a common base plate 1mm on a distance of 6 000 mm The alignment of all drive elements shall be checked after about 100 hours of operation. 3.6 SPEED REDUCERS AND MOTORS 3.6.1 Speed Reducers The speed reducer shall be installed on a plane, stable and rigid base using the fixing bolts as specified in drawings, The speed reducer shall be aligned to the manufacturer's recommendations, The speed reducer shall be aligned within the axial, radial and angular limits as specified by the speed reducer and the drive mechanism manufacturers. For gearing, the bearing surface of the teeth shall be checked using blue paste after a short running period of operation. AA final check of the bearing surface of the teeth shall be performed after a live load running period. If, after the tests the bearing surface is stil on one side of the teeth, the supplier or Site, whichever is the case shall take the necessary measures to correct the alignment. The same shall apply for cases where gears are located between reducer and on outside bearing. Any misalignment shall be corrected. In cases where the base of reducers is provided with threaded holes to facilitate the vertical alignment of the reducers, set screws with jam nuts shall be used. The reducers shall be fixed with precision using metallic packers. After installation on its base and the alignment completed, tighten the holding bolts to the proper torque. To avoid lateral displacement of the reducers, dowel pins or thrust blocks shall be installed, At the installation of the reducers, precautions shall be taken not to abstract the filling and drainage holes of reducers. 3.6.2. Electric Motors Refer to item 3.6.1 - Reducers; any listed item applicable to electric motors shall be used, Install all motors to the location as shown on the drawings and as per technical data, manufacturer's recommendations and this specification. Page 15 0f2037 3.8 SENET 'SP0579.0000-0M5.01 GENERAL MECHANICAL INSTALLATION REV 00 26-11-14.doo HAND ROTATION PRIOR TO COUPLING All rotating equipment shail be hand rotated prior to final coupling. Only tools provided by the equipment supplier or approved by the Engineer shall be used for hand rotating (barring over) any rotating equipment. PREPARATION OF FOUNDATIONS AND PACKERS, The concrete surface shall be chipped or ground by Site for each packer where necessary. This surface shall have a bearing of at least 30% evenly distributed over the entire area of the packer and level to 1 mm/metre, or better, unless otherwise specified by the Engineer. Packers and shims shall be made from stainless steel or primed steel with flat surfaces, free from indents and burrs. The number of shims shall be kept to a minimum by use of suitable thickness packers. Packers shall be sized so that the dead machine load on the packers shall not exceed 3 MPa. The minimum packer size shall be 75 mm x 75 mm unless otherwise specified. This will apply to general work, but where special conditions prevail or heavy loads are being supported, the surface area requirements for packers will be correspondingly greater. There shall be two (2) packers for each holding down boit plus any other intermediate packers necessary to evenly distribute the load and prevent any bending or the introduction of stress into the unit. By written approval of the Engineer at site, the number of packers may be reduced to one (1) per holding down bolt for light equipment. Packing shall be suitably placed so that the bolts can be grouted after the machine has been finally checked. Steel reinforcing may be encountered in the concrete at the packing location. This may be removed by Site if it interferes with the packing, but he shall first consult the Engineer for approval, Units on which the base is not machined shall have all high spots removed from the area on which packers will bear and they shall be set up approximately level on packers with holding down bolts nipped. The top packer shall be 16 mm plate or thicker. This top plate shall be then welded to the base of the unit. Final packing adjustment shall be made between this packer and the one directly below it. Before lowering the unit onto foundation bolts, thoroughly clean the base of burrs, grease and dirt etc The levelling of equipment, using wedges or nuts under base plates shall not be accepted. The minimum gap between equipment and top of concrete shall not be less than 25 mm. Page 16 of 20a9 SENET 'SP0578.00U0-0Ms-01 GENERAL MECHANICAL INSTALLATION REV €0 26-11-14,doe EQUIPMENT MOUNTING BOLTS Bolts fixing mechanical equipment to steel structures shall be installed with one plain hardened washer under the bolt head and one plain hardened and one spring lock washer under the nut. Tapered washers shall be used in lieu of plain washers on tapered surfaces, such as "I" and "U" beam flanges. Mechanical equipment fixed with bolls embedded in masonry or concrete shall incorporate one plain washer and one spring lock washer under the nut Nuts shall be of at least the strength grade appropriate to the grade of bolt of other threaded element with which they are used. Unless otherwise specified, bolts shall be tightened uniformly without over stressing the threads to a "Snug Tightness". This is defined as the tightness obtained by the full effort of a man using a standard length spanner, as listed below. The following table gives maximum torque, which is equal to 65% of the bolt proof load: Torque Diameter Max Spanner Length mm Nm mm M10 7 150 M2. 30 150 M16 74 200 M20 144 250 M24 249 350 M30 496 400 M36 864 450 Boit threads shall be lubricated with Molybdenum disulphide, or approved commercial compound, and shall be free from rust and dirt before tightening. Deformation or "Peening” of bolt threads to prevent rotation of nuts is prohibited. Bolts shall be installed perpendicular to equipment. Small adjustments of the anchor bolts are permitted within the pocket in order to facilitate alignment with the base plate. However, no excessive bending (by means of heating or otherwise) of the anchor bolts will be permitted. Where anchor bolts are substantially misaligned, elongation of the base piate holes wil be permitted with prior approval of the Engineer. Tightened bolts shall project not léss than two full threads through nuts. Maximum projection shall be equal to one third of the bolt diameter and where this necessitates cutting of anchor bolts after installation, the cut ends shall be dressed free of sharp edges and deformed threads shall be made good. Length of "commercial bolts" shall be chosen such that no cutting is required, Unless called for by the drawings or specifications, no holes shail be drilled in structural members without specific permission of the Engineer. Page 17 of 20SENET ‘SPO579-0000-OME.01 GENERAL, MECHANICAL INSTALLATION REV 00 261-14 doe Flame cutting of boltholes is prol ited. Where no anchor bolts are provided, supply chemical type anchors. ‘Where there is more than one (1) bolt to be tightened to hold a particular piece of equipment, the boits shall be tightened in stages so as not to exert uneven siress on the parts being bolted. 3.10 GROUTING "Dry Pack" grout shall not be used unless specifically requested by an equipment supplier and approved by the Engineer. Before grouting, all base plates or equipment shall be properly set on shims and packers, levelled, aligned and pulled down tight with the anchor bolts. Approval of alignment and elevation shall be obtained from the Engineer, in writing, prior to the grouting of the equipment. Grout thickness shall be as shown on drawings. The thickness shall never be less than 25 mm or as recommended by grout manufacturer, whichever is greater. The grout shail be mixed and placed strictly in accordance with the Manufacturer's directions, Grout shall not be placed when vibration from equipment operating nearby is transmitted into the foundation of the equipment being grouted. The grout to foundation contact line shall be cleaned after stripping the grout forms. When necessary, suitable grout holes shall be drilled into equipment base plates to allow removal of air. This shall only be done on written instruction of the Engineer. Exposed and non-load bearing surfaces of foundations shall be finished with a mixture of one part Portland cement and two parts well graded sand, Edges of foundations shall be finished with a 45° chamfer, 3.11 LIFTING LUGS Welded lifting lugs may only be fitted to supplied equipment with the prior approval of the Engineer after the submission of a suitable design and welding procedure in writing, Lifting lugs provided by the Manufacturer shall not be removed, unless the Engineer requests such removal. 3.12 SUPPORTS AND BRACINGS Install all structural supports for equipment as per drawings and specifications or as required. The supports shall be rigid enough to resist fatigue resulting from vibration. Supply also the necessary bracings to prevent any deformation, sagging and ‘excessive vibration on chutework, ductwork or others. Page 18 0120SENET ‘SPOS79.0000-0NG-01 GENERAL MECHANICAL INSTALLATION REV 00 26-11-14.doc 3.13 SAFETY DEVICES ‘Where required, adequate means of protection shall be installed where moving parts represent a hazard. The protection shall be such that it shall not restraint access for lubrication and maintenance purposes. 3.14 LUBRICATION AND CLEANING 3.14.1 All bolts, dowels, screw threads, surfaces in contact, keys and others shall be sprayed with a lubricant product such as "Never Sez" or an approved equal by the Engineers. 3.14.2 Equipment 3.14.21 3.14.2.2 3.14,2.3, 3.14.24 3.14.25 3.14.26 3.14.27 3.14.28 3.14.29 The Engineer shall be requested for the appropriate lubricant product specification from the lubrication data sheets. Rotating equipment, which has been shipped dismantled for assembly in the field or shipped with lubricants, shall have the bearings cleaned, inspected and lubricated, Cifiled gearboxes shall be drained, flushed, cleaned and refilled with type and quantity of oil as recommended by the manufacturer on the lubrication forms or as approved by the Engineer. Site shall notify the Engineer if water is detected in oil sumps or reservoirs. Lubricating grooves, nipples, channels and tubing shall be checked, cleaned and flushed. All oil supply and return piping shali be cleaned and pressure tested in accordance with the Engineers requirements prior to oil fushing. Ensure that all containers used for lubrication are clean to avoid possible contamination. It is forbidden to fil lubricant into the container of another one. The filling of cil pans, gearboxes and the hydraulic unit tanks shall be done to the indicated level on the sight glass. For the filling of hydraulic units cylinder piston rods shall be fully retracted, Ensure that oil pans, gearboxes and oil tanks are free from foreign matter such as water, dirt, plastic, metal chips etc, that could contaminate the lubricant. The filing of fluids into the hydraulic unit tanks from the original containers shall be done using a motorised pump with adequate flexible hoses and fittings to minimise fluid contact with ambient air. All grease shall be supplied in cartridges, Lubrication shall be performed only after equipment is properiy installed, agjusted and aligned. Any abnormal pressure increase causing leaks in the lubrication system shall be eliminated. Page 19 0f20SENET 'SPQ573.0000-0MS-01 GENERAL MECHANICAL INSTALLATION REV 00 26-11-14. doe 3.142.410 Return to the storage facility all the used oils and all the empty, open and full containers used for the lubrication. 3.14.2.11 All bearings shall be lubricated as per the lubrication forms or as per the Engineer's instructions. 3.45 CLEANING Equipment parts shall be thoroughly cleaned of all rust, grt, dirt, grease and other foreign matter, before installation and away from foundations, No kerosene or degreasing solvent shall be used on installed equipment awaiting grouting or where the grout has not fully set. All anti-corrosion applications shall be removed from shafts and machined surfaces prior to the matching part being installed. 3.46 PAINT TOUCH-UP Paint touch-up shali be done when required and specifically at the anchor points of equipment bases. For paint selection and application refer to standard specification no, SP0579-0000- 0W6-01: Corrosion Protection. 4 SAFETY Refer to SP-SHE-03: Project Safety, Health and Environmental Specification Page 20 of20